Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ORIGINAL INSTRUCTIONS
356-5901(GB) V8 06/13
356-5901(GB) V8 06/13
Contents
1.
INTRODUCTION
2.
SAFETY
GENERAL DESCRIPTION
3.1
15
17
General....................................................................................................................................................................................17
356-5901(GB) V8 06/13
4.5 Storage....................................................................................................................................................................................24
4.5.1 Engine Storage.............................................................................................................................................................. 24
4.5.2 Alternator Storage........................................................................................................................................................ 24
4.5.3 Battery Storage............................................................................................................................................................. 24
5.
25
356-5901(GB) V8 06/13
6.
Operation
49
53
7.1
7.2
8.
55
9.
MAINTENANCE
56
356-5901(GB) V8 06/13
1. INTRODUCTION
Thank you for choosing our company to supply your electrical power needs. In line with our policy of continuous product
improvement, we reserve the right to change the information contained within this manual without notice.
This Operator Instruction Manual has been designed to help you operate and maintain your electrical generator set correctly.
We recommend that the operator should take the time to read this manual. Certain tasks may require work to be completed by
specifically trained technicians, an operator should only attempt a task detailed for an operator to complete.
This generator set is one of a family of heavy duty industrial generator sets designed to be ready to run when it arrives. Years of
diesel generator set experience has gone into the set to produce a quality source of electrical power that is efficient and reliable.
Always ensure that maintenance, adjustments and repairs are done by personnel who are authorised to do the work and
have been properly trained. Maintenance and repairs should also be carried out at regular intervals using genuine parts, this
will prolong the life of the generator set. The manufacturer is not liable for any defects or claims due to the users improper
installation, maintenance or use, or for any products which have been modified in any way from the state in which they were sold.
All generator sets should only be operated by those required to do so and therefore be safely kept away from non authorised use.
Some photographs or illustrations in this manual show details or attachments that may be different from your generator set.
These images are for illustrative purposes only. If you have any questions regarding your generator set, please contact your local
Dealer for the latest available information.
Every generator set is uniquely defined by a model number and serial number indicated on a rating plate generally affixed to the
alternator housing (See Section 3.1). This information is required when ordering spare parts or when service or warranty work is
required.
356-5901(GB) V8 06/13
2. SAFETY
2.1 General
The generator set is designed to be safe when used in the correct manner. Responsibility for safety, however, rests with the
personnel who use the set. Before performing any procedure or operating technique, it is the users responsibility to ensure that
it is safe to do so.
Warning:
II Read and understand all safety precautions and warnings before operating the generator set.
II Failure to follow the instructions, procedures and safety precautions in this manual may increase the possibility of
accidents and injuries.
II Never start the generator set unless it is safe to do so.
II Do not attempt to operate the generator set with a known unsafe condition.
II If the generator set is unsafe, fit danger notices and disconnect the battery negative () lead so that it cannot be
started until the condition is corrected.
II Ensure the generator set is protected from any unauthorised use, use signs were appropriate.
II Disconnect the battery negative () lead prior to attempting installation, repairs or cleaning on the generator set.
II Install and operate this generator set only in full compliance with relevant National, Local, or Federal Codes,
Standards or other requirements.
Warning
II Familiarise yourself with the location of the Emergency Stop Button. Emergency shutoff controls
are for EMERGENCY use ONLY.
II DO NOT use emergency shutoff devices or controls for normal stopping procedure.
II Do not start the engine until the problem necessitating the emergency stop has been located and corrected.
356-5901(GB) V8 06/13
Ensure that all protective guards and all covers are secured in place on the engine.
Never put maintenance fluids into glass containers. Glass containers can break.
Use all cleaning solutions with care.
Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
The engine is stopped. Ensure that the engine cannot be started.
Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the
battery ground leads. Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or
repair the equipment.
Note:
Dispose of all fluids according to local regulations and mandates.
356-5901(GB) V8 06/13
Warning
II Do not charge a frozen battery, this may cause an explosion.
II Ensure the generator set room is properly ventilated.
II Keep the room, the floor and the generator set clean. When spills of fuel, oil, battery
electrolyte or coolant occur, they should be cleaned up immediately.
II Never store flammable liquids near the engine.
II Store oily rags in covered metal containers.
II Do not smoke or allow sparks, flames or other sources of ignition around fuel or batteries. Fuel vapours are
explosive. Hydrogen gas generated by charging batteries is also explosive.
II Avoid refilling the fuel tank while the engine is running.
II Do not attempt to operate the generator set with any known leaks in the fuel system.
II Do not use aerosol types of starting aids such as ether. Using these types of items could result in an explosion and
personal injury.
356-5901(GB) V8 06/13
Warning
II Engine exhaust contains products of combustion which may be harmful to your health.
2.6 Mechanical
The generator set is designed with guards for protection from moving parts. Care must still be taken to protect personnel and
equipment from other mechanical hazards when working around the generator set.
Warning:
II Do not attempt to operate the generator set with safety guards removed. While the generator set is running do not
attempt to reach under or around the guards for any reason.
II Keep hands, arms, long hair, loose clothing and jewellery away from pulleys, belts and other moving parts. Some
moving parts can not be seen clearly when the set is running.
II Keep access doors on enclosures, if equipped, closed and locked when not required to be open.
II Avoid contact with hot oil, hot coolant, hot exhaust gases, hot surfaces, sharp edges and corners.
II Wear protective clothing including gloves and hat when working around the generator set.
2.7 Chemical
Fuels, oils, coolants, lubricants and battery electrolyte used in this generator set are typical of the industry. However, they can be
hazardous to personnel if not treated properly. The disposal of fuels, oils, coolants, lubricants, battery electrolyte and batteries
should be carried out in accordance with local government laws and regulations.
2.7.1 Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all
hoses to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the cooling system is drained. Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
2.7.2 Oils
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot
components to contact the skin.
2.7.3 Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear
protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.
Warning:
II Do not swallow or have skin contact with fuel, oil, coolant, lubricants or battery electrolyte. If swallowed, seek
medical treatment immediately. Do not induce vomiting if fuel is swallowed. For skin contact, wash with soap and
water.
II Do not wear clothing that has been contaminated by fuel or lube oil.
II It is recomended to check the electrolyte level in accessible batteries every 500 hours.
10
356-5901(GB) V8 06/13
2.8 Noise
Sound levels will vary depending on the configuration of the generator set and the final installation of the generator set.
Refer to the following for factors that influence the level of exposure:
The characteristics of the area around the generator set
Other sources of noise
The number of machines and other adjacent processes
The length of time of exposure to the noise
This information will enable the user of the machine to evaluate the hazard and the risk.
Warning:
II Prolonged exposure to noise levels above 80 dBA is hazardous to hearing.
II Ear protection must be worn when operating or working around an operating generator set.
2.9 Electrical
Warning
II Before the generator set is operated please consult your local dealer to establish whether an NEL has been fitted.
As more than one NEL per site may be unsafe, it is important to establish whether one has already been installed on
site.
Warning:
II Ensure the generator set, including a mobile set, is effectively grounded/earthed prior to operation.
II Do not touch electrically energised parts of the generator set and/or interconnecting cables or conductors with any
part of the body or with any non insulated conductive object.
II Use only Class BC or Class ABC extinguishers on electrical fires.
II For generator sets with external socket outlets only Residual Current Device (RCD) protection on socket outlets,
where fitted, is designed to operate within a TN earthing system. Ensure local wiring regulations are met prior
to generator set operation and that all equipment connected via the generator set sockets, including plugs and
electrical cables, are of the correct specification and are known to be in a safe and undamaged condition.
11
356-5901(GB) V8 06/13
BREATHING:
1. Check that the victim is breathing by looking, listening and feeling for the breath.
CIRCULATION:
1. Check for pulse in the victims neck or wrist.
IF NO BREATHING BUT PULSE IS PRESENT:
1. Pinch the victims nose firmly.
2. Take a deep breath and seal your lips around the victims lips.
3. Blow slowly into the mouth watching for the chest to rise. Let the chest fall completely. Give
breaths at a rate of 10 per minute.
4. If the victim must be left to get help, give 10 breaths first and then return quickly and
continue.
5. Check for pulse after every 10 breaths.
6. When breathing restarts, place the victim into the recovery position described later in this
section.
IF NO BREATHING AND NO PULSE:
1. Call or telephone for medical help.
2. Give two breaths and start chest compression as follows:
3. Place heel of hand 2 fingers breadth above ribcage/breastbone junction.
4. Place other hand on top and interlock fingers.
5. Keeping arms straight, press down 45 cm (1.52 inch) 30 times at a rate of 100 per minute.
There should be equal timing between chest compression and release.
6. Repeat cycle (2 breaths, 30 compressions) until medical help takes over.
7. If condition improves, confirm pulse and continue with breaths. Check for pulse after every 10
breaths.
8. When breathing restarts, place the victim into the recovery position.
WARNING
II Do not apply pressure over the ribs, lower tip of the victims breastbone or the abdomen.
RECOVERY POSITION:
1. Turn the victim onto the side.
2. Keep the head tilted with the jaw forward to maintain the open airway.
3. Make sure the victim cannot roll forwards or backwards.
4. Check for breathing and pulse regularly. If either stops, proceed as above.
Warning:
II Do not give liquids until victim is conscious.
12
356-5901(GB) V8 06/13
Oil Drain
Earth
Coolant Drain
Electric Shock
Do Not Touch
Hot Surface
Warning
Crush Falling Object
Shock Warning
Lift Symbol
13
Centre of Gravity
356-5901(GB) V8 06/13
X Kg
(X LBS)
No Naked Flames
Battery Acid
Explosive Gas
Do NOT Powerwash
Sheild Eyes
14
356-5901(GB) V8 06/13
3. GENERAL DESCRIPTION
This generator set has been designed as a complete package to provide superior performance and reliability.
Each generator set is provided with a Rating Plate generally affixed to the alternator housing / panel enclosure. This label
contains the information needed to identify the generator set and its operating characteristics. This information includes, but is
not limited to, the model and serial numbers, output characteristics such as voltage, phase and frequency, output rating in kVA
and kW and rating type (basis of the rating). The model and serial numbers uniquely identify the generator set.
The diesel engine powering the generator set has been chosen for its reliability and the fact that it has been specifically designed
for powering generator sets. The engine is of the heavy duty industrial type with 4 stroke compression ignition and is fitted with
all accessories to provide a reliable power supply.
The engine electrical system is either 12 or 24 volts DC depending on the size of the set.
The engine cooling system comprises of a radiator, a high capacity pusher fan and a thermostat. The main AC alternator has its
own internal fan to cool the alternator components.
The output electrical power is produced by an alternator fine tuned to the output of this generator set.
The engine and alternator are coupled together and mounted on a heavy duty steel base frame. The base frame incorporates an
integrated or polyethylene fuel tank except for the largest sets (approximately 1,000 kVA and above).
The generator set is fitted with vibration isolators which are designed to reduce engine vibration being transmitted to the
foundation on which the generator set is mounted. These isolators are fitted between the engine/alternator feet and the base
frame. Alternatively, on 4008, 4012 and 4016 powered models the engine/alternator is rigidly mounted on the base frame and
the vibration isolators are supplied loose to be fitted between the base frame and the foundation.
An exhaust silencer is provided loose for installation with the generator sets. The silencer and exhaust system reduce the noise
emission from the engine and can direct exhaust gases to safe outlets.
One of several types of control systems and panels is fitted to control the operation and output of the generator set and to
protect the set from possible malfunctions. Section 5 of this manual provides detailed information on these systems and will aid
in identification of the control system fitted on the generator set.
To protect the alternator, a suitably rated circuit breaker selected for the generator set model and output rating is supplied
mounted in a steel enclosure.
GENERATING SET
MANUFACTURER
MODEL
SERIAL NUMBER
SALES ORDER REF.
YEAR OF MANUFACTURE
AMBIENT TEMP
RATED POWER
STANDBY
PRIME
RATED VOLTAGE
PHASE
RATED POWER FACTOR
RATED FREQUENCY
RATED CURRENT - STANDBY
RATED CURRENT - PRIME
RATED RPM
ALTITUDE
ALTERNATOR CONNECTION
ISO8528 - 3 RATING
ALTERNATOR ENCLOSURE
INSULATING CLASS
EXCITATION VLOTAGE
EXCITATION CURRENT
AVR
MASS
ISO 8528
XXXXXXXXXXXXXXXXX
XXXXXX/XX
2010
25
C
88.0
70.4
80.0
64.0
400/230
3
0.80
50
127
115
1500
152.4
S-STAR
PR 500H TL0.875
23
H
29
2
R438C
1463
kVA
kW
kVA
kW
V
COS
Hz
A
A
rpm
m
1.
2.
1.
2.
3.
4.
5.
6.
3.
4.
IP
V
A
5.
kg
This generator set is designed to operate in ambient temperatures up to 50 deg C and at higher altitudes
6.
356-5901(GB) V8 06/13
16
12
11
14
16
15
17
18
19
20
Figure 3.2 Typical Generator set Description (this may differ from the Generator set you have received)
13
10
6
2
21
II G
enerator sets contain moving
parts and hot surfaces. Wear the
appropraite PPE as required.
* = Opposite side
1. Radiator
2. Radiator Fill
3. Battery Charging Alternator
4. Exhaust
5. Turbo
6. Oil Filter*
7. Air Filter
8. Alternator
9. Emergency Stop Pushbutton
10. Control Panel
11. Circuit Breaker
12. Base Frame
13. Cable Entry
14. Starter Motor
15. Battery
16. Fuel Fill*
17. Lifting Points
18. Jacket Water Heater
19. Anti Vibration Mounts*
20. Drag Points
21. Fan Guards
356-5901(GB) V8 06/13
Figure 4.1 Typical installation showing generator set ventilation
Protection from the elements such as rain, snow, sleet, wind driven precipitation, flood water, direct sunlight, freezing
temperatures or excessive heat.
Protection from exposure to airborne contaminants such as abrasive or conductive dust, lint, smoke, oil mist, vapours,
engine exhaust fumes or other contaminants.
Protection from impact from falling objects such as trees or poles, or from motor vehicles or lift trucks.
Clearance around the generator set for cooling and access for service: at least 1 metre (3ft 3in) around the set and at least
2 metres (6ft 6in) headroom above the set. (See Figure 4b)
Access to move the entire generator set into the room. Air inlet and outlet vents can often be made removable to provide
an access point.
Limited access to unauthorised personnel.
If it is necessary to locate the generator set outside of the building, the generator set should be enclosed in a weatherproof
canopy or container-type housing which is available for all sets.
Figure 4.2 Typical installation showing generator set access and operator workstation
17
356-5901(GB) V8 06/13
Warning:
II Make sure all personnel are out of the canopy or container, if equipped, before closing and latching enclosure doors.
II Before closing canopy or enclosure doors, ensure all obstructions (especially hands and fingers) are clear to prevent
damage or injury.
II For transport purposes, some silencer outlets on generator sets housed in walk-in type enclosures will be fitted with
cover plates. These are to be replaced with the supplied stub pipes complete with fitted rain hood.
II Ensure there is no debris on the base frame prior to starting, as loose items will cause radiator damage.
Because enclosed generator sets are easily transportable and may be installed and operated in a temporary location, many of
the fixed installation details given in this chapter may not apply. The following considerations must be taken into account when
temporarily installing the generator set:
Locating the generator set where it will be protected from damage and away from the exhaust
fumes of other engines or other airborne contaminants such as dust, lint,
smoke, oil mist or vapours.
Ensure the generator set is not positioned in such a way that it will obstruct the entrance or
exit to the area where the it is situated.
Locating the generator set on firm, level ground which will not subside or be otherwise
affected by the vibration caused by the operation of the generator set
Ensuring that fumes from the exhaust outlet will not be a hazard especially when wind
is taken into account.
Ensure there is enough area around the generator set for access and serviceability.
Electrical grounding of the generator set at all times, in accordance with local regulations.
Providing access to refill the fuel tank when required.
Protecting electrical cables installed between the generator set and the load. If these are laid
on the ground ensure they are boxed in or covered to prevent damage or injury to personnel.
WARNING
II Enclosed generator sets should be installed outside. In the event that the enclosed
generator set is installed inside, adequate fresh cooling air must be provided and that
both engine and hot coolant air exhausts must be ducted outside the building. The
ducting and exhaust pipework must be designed to minimise back pressure which would
have a detrimental effect on generator set performance.
18
356-5901(GB) V8 06/13
Warning:
II For generator sets housed in walk-in type containers, crankcase breather outlets terminated at the external face of
the enclosure will be plugged. These must be removed prior to operation.
Warning:
II Always use wood between forks and the base frame to spread the load and also between the forklift carriage and
the side of the canopy to prevent damage.
Figure 4.4 Transporting a generator set using a forklift truck and forklift trolley
19
356-5901(GB) V8 06/13
1. Forklift Pockets
2. Oil FIeld Skid
Figure 4.5 Typical generator set with Oil Field Skid base option
If the generator set will be regularly moved, it should be fitted with the optional Oil Field Skid which provides forklift pockets in
the base frame along with eyes for pulling. The smaller sets have forklift pockets in the base frame as standard.
Warning:
II Please ensure the fuel tank is empty when lifting the generator set to ensure safe and stable lifting.
II Never lift the generator set by attaching to the engine or alternator lifting lugs.
II Ensure the lifting rigging and supporting structure is in good condition and is suitably rated.
II Keep all personnel away from the generator set when it is suspended.
To lift and install the generator set you can use the single / two point lifting points or the lifting points provided on the baseframe.
Points of attachment should be checked for cracked welds or loose nuts and bolts before lifting. A spreader bar is required to
prevent damage to the generator set whilst lifting from the baseframe (see Figure 4h). It should be positioned over the centre of
gravity, to allow a vertical lift. Guide ropes should be used to prevent twisting or swinging of the generator set once it has been
lifted clear of the ground. Place the generator set down on a level surface capable of supporting its weight.
1
1. Single Point Lift
20
356-5901(GB) V8 06/13
Warning
II Please ensure the fuel tank is empty when lifting the generator set to ensure safe and stable lifting.
II Centre of gravity decal is located on the base / canopy of the generator set.
II The centre of gravity may not always be located at the centre of the generator set.
II Do not attempt to lift in high winds.
1. Spreader Bar
Figure 4.8 Proper lifting arrangement for installing the generator set (open & enclosed)
21
356-5901(GB) V8 06/13
Loaded / Unloaded
Method
Top Lift
Unloaded Only
Top Lift
Loaded
Bottom Lift
Loaded
Bottom Lift
Diagram
Loaded / Unloaded
Method
Bottom Lift
Diagram
22
356-5901(GB) V8 06/13
1. Vibration Isolators
2. Flexible Exhaust Coupling
3. Flexible Air Discharge Duct
4.4.1 Foundation
A reinforced concrete pad makes the best foundation for the generator set. It provides a rigid support to prevent deflection
and vibration. Typically the foundation should be from 150 mm to 200 mm (6 to 8 inches) deep and at least 150 mm (6 inches)
wider and longer than the generator set. The ground or floor below the foundation should be properly prepared and should
be structurally suited to carry the combined weight of the foundation pad and the generator set. (If the generator set is to be
installed above the ground floor the building structure must be able to support the weight of the generator set, fuel storage and
accessories.) Relevant building codes should be consulted and complied with. If the floor is wet from time to time, such as in
a boiler room, the pad should be raised above the floor. This will provide a dry footing for the generator set and for those who
connect, service or operate it. It will also minimise corrosive action on the base frame.
23
356-5901(GB) V8 06/13
4.5 Storage
Long term storage can have detrimental effects on both the engine and alternator. These effects can be minimised by properly
preparing and storing the generator set.
24
356-5901(GB) V8 06/13
5
7
8
2
4
9
25
356-5901(GB) V8 06/13
1. AC Voltmeter indicates the AC voltage generated at the alternator output terminals. The reading indicated on the
voltmeter will vary depending on the position of the voltmeter selector switch (item 2). It should not, however, vary while
the generator set is operating. If the meter gives no reading while the generator set is running, ensure that the AC voltmeter
selector switch is not in the OFF position.
2. AC Voltmeter Selector Switch allows the operator to select voltage reading between phases or between a phase and
neutral. The OFF position allows the voltmeter zero position to be checked while the generator set is running.
3. AC Ammeter indicates the AC electrical current being delivered which is dependant on the connected load. A separate
reading from each of the phases is possible using the ammeter selection switch (item 4). If the meter gives no reading while
the generator set is running, ensure that the AC ammeter selector switch is not in the OFF position.
4. AC AMMETER SELECTOR SWITCH allows the operator to select a current reading from each of the phases. The OFF position
allows the ammeter zero position to be checked while the generator set is running.
5. FREQUENCY METER Indicates the output frequency of the generator set. At partial load the frequency will be slightly higher
than normal, depending on the droop of the governor. In practice, no load frequencies of approximately 52 and 62 Hz for
50 Hz and 60 Hz respectively, are considered normal. The frequencies will fall, as the generator set is loaded, to 50 Hz and 60
Hz at full load.
6. HOURS RUN METER indicates the total number of hours of generator set operation. This meter assists with maintenance.
7. FAULT INDICATOR LAMPS (where fitted) illuminate to indicate that the protective circuitry has sensed the indicated condition.
The lamp should be red on conditions for which the system will initiate a shutdown of the generator set. For alarms, the lamp
can be red or amber.
1
2
3
1.
2.
3.
4.
5.
6.
26
356-5901(GB) V8 06/13
Warning
II The following checks detailed below are the only tasks that an operator should undertake.
The following checks should be performed prior to starting the generator set:
1. Ensure the Control Switch / Key Switch is Off.
A visual inspection should take only a few minutes and can prevent costly repairs and accidents For maximum generator set life,
visually inspect the generator set before starting. Look for items such as:
Loose fastenings / fixings, worn belts or loose connections. Repair as necessary.
The fan and exhaust guards must be at the correct positions and securely fixed. Repair damaged / loose guards or renew
missing guards.
Wipe clean all filler caps before the engine is serviced or fluids are topped up to reduce the chance of any system
contamination.
For any type of leak (coolant, lubricating oil or fuel), clean away the fluid. If a leak is observed, find the source and correct
the leak. If a leak is suspected, check the fluid levels frequently until the leak is found and repaired.
Accumulated grease and/or oil on an engine is a fire hazard. Remove it by steam cleaning or by the use of a high pressure
water jet. Avoid highpressure water on the electronic / electrical components, provide suitable protection were possible.
Ensure that the coolant pipes are fitted correctly and that they are secure. Check for leaks. Check the condition of all pipes
for splits or signs of rubbing.
Fluid levels
2. Check the engine oil and coolant levels replenish as necessary (see engine handbook for locations).
Ensure fluids used are as recommended within the engine handbook.
Warning:
II Do not remove the radiator cap or any component of the cooling system while the engine is running and while the
coolant is under pressure, because dangerous hot coolant can be discharged, posing a risk of personal injury.
Do not add large amounts of cold coolant to a hot system as serious engine damage could result.
Note:
Diesel engines normally consume lube oil at a rate of 0.25% to 1% of the fuel consumption at full load.
When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the engine.
Always top up when engine is cold.
Warning:
II When filling the fuel tank, do not smoke or use an open flame in the vicinity.
3. Check the fuel level fill as necessary.
27
356-5901(GB) V8 06/13
Warning:
II Before tightening the fan belts, disconnect the battery negative () lead to ensure the engine cannot be accidentally
started.
4. Check the condition and tension of the fan and engine alternator belts tighten as necessary.
5. Check all hoses for loose connections or deterioration tighten or replace as necessary.
6. Check the battery terminals for corrosion clean as necessary.
Warning:
II When working with the batteries, do not smoke or use an open flame in the vicinity. Hydrogen gas from batteries is
explosive.
II Do not short the positive and negative terminals together.
7. Check the battery electrolyte level fill with distilled water as necessary.
8. Check the control panel and the generator set for heavy accumulation of dust and dirt clean as necessary. These can pose
an electrical hazard or give rise to cooling problems.
9. Check the air filter restriction indicator, if fitted replace the filter as necessary.
10. Clear the area around the generator set of any insecure items that could inhibit operation or cause injury. Ensure cooling air
ventilation screens are clear.
11. Visually check the entire generator set for signs of leaks from the fuel system, cooling system or lubrication seals.
12. Periodically drain exhaust system condensate traps, if equipped.
13. Ensure the alternator output circuit breaker is in the OFF (handle down) position.
Note:
The generator set may be stopped at any time by turning the Key Switch to Position 0 (Off ).
Note:
In the event of low battery voltage the LED will indicate on the 1002T PCB (see Figure 5a 8). There is no battery voltmeter
on 1002T panel.
The engine will not start if any fault indicators are illuminated. Reset the control system by turning the Key Switch to
Position 0 (Off ). Ensure the faults have been corrected prior to attempting to start the generator set.
Warning:
II The Key Switch must not be turned to position
or position
7. Start: Turn the Key Switch from Position 0 (Off ) through Position 1 (On) to Position
(Thermo) to activate the
thermostart, if fitted. Hold for 7 seconds to preheat the induction air. After this time, the Key Switch should be further turned
to Position (Start) to crank the engine. When the engine starts, release the Key Switch immediately allowing it to return to
Position 1 (On).
Do not crank the engine for more than 5 to 7 seconds should the engine fail to start. Allow an interval of 10 seconds and
always turn the Key Switch to Position 0 (Off ) between cranking attempts. If, after 4 cranking attempts, the engine still has
not started, please refer to a qualified generator set technician to determine the cause of failure to start.
28
356-5901(GB) V8 06/13
Note:
Load can now be applied to the generator set. However, the maximum step load that can be accepted in any one step is
dependent on the operating temperature of the generator set.
Shutdown:
8. To shut the generator set down, turn off the load by switching the Alternator Output Circuit Breaker to OFF (handle down).
Allow the generator set to run without load for a few minutes to cool. Then turn the Key Switch to Position 0 (Off ). The
generator set will shutdown.
In case of an emergency where immediate shutdown is necessary, the Key Switch should be turned to Position 0 (Off )
immediately without disconnecting the load.
Note:
Turning the Key Switch to Position 0 (Off ) will also reset the protective circuits after a fault has been detected. Ensure that
the fault has been rectified prior to restarting the generator set.
When high engine temperature is sensed, the red coloured fault lamp labelled HIGH ENGINE TEMPERATURE illuminates
(see Figure 5b) and the generator set is automatically shut down. The fault lamp will remain illuminated and the engine locked
out until the fault has been acknowledged and reset by turning the Key Switch to Position 0 (Off ). On some larger models a low
coolant level sensor will also cause the generator set to shutdown and will also illuminate the HIGH ENGINE TEMPERATURE fault
lamp even though the temperature may be in the normal range.
When low lube oil pressure is sensed the LOW OIL PRESSURE fault lamp illuminates and the generator set is automatically shut
down. Reset is effected by turning the Key Switch to Position 0 (Off ).
Warning
II If at any time the generator set stops because of a fault, the fault should be rectified before trying to restart the
generator set
Fault
Symptom
Remedy
29
1. C
heck Coolant Level. (Be Sure To Allow The generator set
To Cool First As Hot Water/Steam Can Be Present When
You Remove The Radiator Cap).
2. Refer To Your Local Dealer.
Refer To Your Local Dealer.
356-5901(GB) V8 06/13
1. Display screen
2. AC overview key
3. Engine overview key
4. Main menu or home key
5. Alarm acknowledge key
6. Event reset key
7. Event log key
8. Auto key
9. Stop key
10. Run key
11. Escape key
12. Up key
13. Right key
14. OK or Enter key
15. Down key
16. Left key
30
356-5901(GB) V8 06/13
Warning
II The following checks detailed below are the only tasks that an operator should undertake.
The following checks should be performed prior to starting the generator set:
1. A visual inspection should take only a few minutes and can prevent costly repairs and accidents For maximum generator set
life, visually inspect the generator set before starting. Look for items such as:
Loose fastenings / fixings, worn belts or loose connections. Repair as necessary.
The fan and exhaust guards must be at the correct positions and securely fixed. Repair damaged / loose guards or renew
missing guards.
Wipe clean all filler caps before the engine is serviced or fluids are topped up to reduce the chance of any system
contamination.
For any type of leak (coolant, lubricating oil or fuel), clean away the fluid. If a leak is observed, find the source and correct
the leak. If a leak is suspected, check the fluid levels frequently until the leak is found and repaired.
Accumulated grease and / or oil on an engine is a fire hazard. Remove it by steam cleaning or by the use of a high pressure
water jet. Avoid high-pressure water on the electronic/electrical components provide suitable protection were possible.
Ensure that the coolant pipes are fitted correctly and that they are secure. Check for leaks. Check the condition of all pipes
for splits or signs of rubbing.
Fluid levels
2. Check the engine oil and coolant levels replenish as necessary (see engine handbook for locations). Ensure fluids used are as
recommended within the engine handbook.
Warning:
II Do not remove the radiator cap or any component of the cooling system while the engine is running and while the
coolant is under pressure, because dangerous hot coolant can be discharged, posing a risk of personal injury. Do
not add large amounts of cold coolant to a hot system as serious engine damage could result.
3. Check the engine oil and coolant levels replenish as necessary.
Note:
Diesel engines normally consume lube oil at a rate of 0.25% to 1% of the fuel consumption.
When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the engine.
Always top up when engine is cold.
Warning:
II When filling the fuel tank, do not smoke or use an open flame in the vicinity.
4. Check the fuel level fill as necessary.
Warning:
II Before tightening the fan belts, disconnect the battery negative () lead to ensure the engine cannot be accidentally
started.
5. Check the condition and tension of the fan and engine alternator belts tighten as necessary.
6. Check all hoses for loose connections or deterioration tighten or replace as necessary.
7. Check the battery terminals for corrosion clean as necessary.
Warning:
II When working with the batteries, do not smoke or use an open flame in the vicinity. Hydrogen gas from batteries is
explosive.
II Do not short the positive and negative terminals together.
31
356-5901(GB) V8 06/13
8. Check the battery electrolyte level fill with distilled water as necessary.
9. Check the control panel and the generator set for heavy accumulation of dust and dirt clean as necessary. These can pose
an electrical hazard or give rise to cooling problems.
10. Check the air filter restriction indicator, if fitted replace the filter as necessary.
11. Clear the area around the generator set of any insecure items that could inhibit operation or cause injury. Ensure cooling air
ventilation screens are clear.
12. Visually check the entire generator set for signs of leaks from the fuel system, cooling system or lubrication seals.
13. Periodically drain exhaust system condensate traps, if equipped.
14. Ensure the Alternator Output Circuit Breaker is in the OFF (handle down) position.
32
356-5901(GB) V8 06/13
Note:
When not using PowerWizard in AUTO mode a Not in Auto Mode activate alarm will sound (where enabled).
33
356-5901(GB) V8 06/13
34
356-5901(GB) V8 06/13
Control Keys:
RUN Pressing the Run key will cause the engine to enter the run mode.
AUTO Pressing the Auto key will cause the engine to enter the auto mode.
STOP Pressing the Stop key will cause the engine to enter stop mode.
Navigation Keys:
Scroll Up The Scroll Up key is used to navigate up through the various menus or monitoring screens. The Scroll Up key is also
used during setpoint entry. During numeric data entry the Scroll Up key is used to increment the digits (09). If the setpoint
requires selection from a list, the Scroll Up key is used to navigate through the list.
Escape The Escape key is used during menu navigation in order to navigate up through the menu/sub-menu structure. Each
key press causes the user to move backwards/upwards through the navigation menus. The Escape key is also used to exit/
cancel out of data entry screens during setpoint programming. If the Escape key is pressed during setpoint programming,
none of the changes made on screen will be saved to memory.
Scroll Right The Scroll Right key is used during setpoint adjustment. During numeric data entry, the Scroll Right key is used to
choose which digit is being edited. The Scroll Right key is also used during certain setpoint adjustments to select or deselect a
check box. If a box has a check mark inside, pressing the Scroll Right key will cause the check mark to disappear, disabling the
function. If the box does not have a check mark inside, pressing the Scroll Right key will cause a check mark to appear, enabling
the function.
OK
Enter / OK The Enter key is used during menu navigation to select menu items in order to navigate forward/downward in
the menu/submenu structure. The Enter key is also used during setpoint programming in order to save setpoint changes.
Pressing the Enter key during setpoint programming causes setpoint changes to be saved to memory.
Scroll Down The Scroll Down key is used to navigate down through the various menus or monitoring screens. The Scroll
Down key is also used during setpoint entry. During numeric data entry the Scroll Down key is used in order to decrement the
digits (09). If the setpoint requires selection from a list, the Scroll Down key is used to navigate down through the list.
Scroll Left The Scroll Left key is used during setpoint adjustment. During numeric data entry, the Scroll Left key is used to
choose which digit is being edited. The Scroll Left key is also used during certain setpoint adjustments to select or deselect a
check box. If a box has a check mark inside, pressing the Scroll Left key will cause the check mark to disappear, disabling the
function. If the box does not have a check mark inside, pressing the Scroll Left key will cause a check mark to appear, enabling
the function.
Event Keys and Indicators:
Yellow Warning Light A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light
indicates that there are acknowledged warnings active. If there are any active warnings, the yellow light will change from
flashing yellow to solid yellow after the Alarm Acknowledge key is pressed. If there are no longer any active warnings, the
yellow light will turn off after the Alarm Acknowledge key is pressed.
Red Shutdown Light A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light
indicates that there are acknowledged shutdown events active. If there are any active shutdown events the red light will
change from flashing red to solid red after the Alarm Acknowledge key is pressed. Any condition that has caused a shutdown
event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.
Alarm Acknowledge Pressing the Alarm Acknowledge will cause the horn relay output to turn off and silence the horn.
Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status
of the alarms.
Event Reset Key Pressing the Event Reset key will reset all events when the control is in the stopped position. However, Reset
All Events will not reset Present events.
35
356-5901(GB) V8 06/13
Event Log Key Pressing the Event Log key will navigate to the Active Events menu. In order to scroll through the events, use
the up and down keys. After highlighting an event, press the OK key to see information about the event such as the SPN and
the FMI.
EMERGENCY STOP Push button A red lock-down push button that immediately shuts down the generator set and will inhibit
start until the push button has been released by turning it clockwise. Prior to restarting the set, this fault must be reset by
pressing the stop button on the module and resetting the fault in the event log menu.
Note:
To reset the menu back to the start, please press the Escape key three times.
Event Viewing
There are two ways to view events. Pressing the EVENT LOG key navigates directly to the ACTIVE EVENTS menu. The other way is
to use the Main Menu:
1. From the MAIN MENU/VIEW, highlight EVENT LOGS and press the Enter key. The ACTIVE EVENTS menu will be displayed in
this menu.
2. In order to scroll through the events use the up and down keys. Events are ordered with present events first, active events next
and inactive events last. Within these classifications they are ordered by engine run hours (or real time clock on
PowerWizard 2.1).
3. Press Enter after highlighting an event to see additional information such as SPN, FMI, time and date of first occurrence, time
and date of last occurrence (PowerWizard 2.1 only), engine hours at first occurrence and engine hours at last occurrence.
Quick Shut Down Resetting
In addition to the above procedure there is also a simplified process for resetting all events. To reset all events:
1. Ensure that the control is in the stopped position.
2. Press the Reset Event key from any screen.
3. A confirmation prompt will appear.
4. Press the OK key to reset all events on all modules. Press the ESCAPE key to cancel the reset operation.
Note:
The PowerWizard must be in stop mode to reset events.
Present events cannot be reset.
36
356-5901(GB) V8 06/13
5.3.8 Security
There are 3 levels of password protection on the PowerWizard control panel. All of the adjustable setpoints are associated with a
specific level of security required to make an adjustment to the parameter. The passwords only affect changing setpoints within
the control panel.
The level of password protection that is required for each setpoint is identified on the parameter setpoint entry screen. A security
level identification number 1, 2 or 3 next to a padlock symbol is displayed on the parameter setpoint entry screen. A Level
3 security is used for the most secure setpoints and Level 1 security is used for the least secure setpoints. If the PowerWizard is
currently at the required level of protection when viewing a parameter, the padlock will not appear.
If a parameter is displayed with a padlock but no security level identification number next to it, the parameter cannot be changed
from the PowerWizard display and the Dealer must be contacted. Level 1 and 2 passwords are disabled when installed. Level 1
and 2 passwords are user level passwords and can be used if desired.
The PowerWizard 2.1 also has a SCADA password, which can be used to secure remote communications.
To view the security menu:
MAIN MENU > CONFIGURE > SECURITY.
At the top of the security menu the current security level is displayed. Within the security menu are the following options:
DROP TO MINIMUM LEVEL used to return the current security level to the lowest level set-up. Highlight and press Enter to drop
to minimum security level. If no Level 1 or 2 passwords are set-up the minimum level will be 2. If a Level 2 password is set-up, the
minimum level will be 1 and if a Level 1 password is set-up the minimum level will be 0.
ENTER LEVEL 1 OR 2 used to enter Level 1 or 2 passwords. Highlight and press Enter to proceed to the password entry screen.
Passwords can be entered using the cursor keys. In PowerWizard, Level 1 and 2 passwords must be different. An entered
password is compared against the stored Level 1 and 2 passwords, if the password is correct the PowerWizard will go to the
corresponding security level.
ENTER LEVEL 3 used to obtain Level 3 access. The Level 3 security password is reserved for critical setpoints that should only be
changed by a skilled operative. As such you must contact your Dealer if you require a change associated with a Level 3 password.
CHANGING LEVEL 1 PASSWORD used to set-up, change or disable a Level 1 password. In order to use this feature the control
must be at current security Level 1 or higher. Highlight and press Enter to proceed to the password entry screen. To set-up or
change the password, enter the new password using the cursor keys. Passwords may be 16 digits long. To disable the Level 1
security password, set the password to 0. Press the Enter key to save.
CHANGING LEVEL 2 PASSWORD used to set-up, change or disable a Level 2 password. In order to use this feature the control
must be at current security Level 2 or higher. Highlight and press Enter to proceed to the password entry screen. To set-up or
change the password, enter the new password using the cursor keys. Passwords may be 16 digits long. To disable the Level 2
security password, set the password to 0. Press the Enter key to save.
CHANGING SCADA PASSWORD (PowerWizard 2.1 only) used to set-up, change or disable a SCADA password. Highlight and
press enter to proceed to the password entry screen. To set-up or change the password, enter the new password using the cursor
keys. Passwords may be 16 digits long. To disable the SCADA security password, set the password to 0. Press the Enter key to save.
37
356-5901(GB) V8 06/13
2. To start or stop the fuel pump, highlight the PUMP CONTROL then press the OK key.
3. Use the cursor key to select START FUEL PUMP or STOP FUEL PUMP and press the OK key.
4. Auto Fuel Load Pump On and Off thresholds are set at 25% and 75% respectively.
38
356-5901(GB) V8 06/13
Fault
Symptom
Remedy
1. C
heck Coolant Level In The Radiator. Refer To Safety
Section Before Removing The Radiator Cap
2. Refer To Your Local Dealer
1. C
heck That The Generator set Stops When The
Emergency Stop Push button Is DepRessed
2. Refer To Your Local Dealer
39
356-5901(GB) V8 06/13
356-5901(GB) V8 06/13
Warning
II The following checks detailed below are the only tasks that an operator should undertake.
The following checks should be performed prior to starting the generator set:
1. A visual inspection should take only a few minutes and can prevent costly repairs and accidents for maximum generator set
life, visually inspect the generator set before starting. Look for items such as:
Loose fastenings / fixings, worn belts or loose connections. Repair as necessary.
The fan and exhaust guards must be at the correct positions and securely fixed. Repair damaged / loose guards or renew
missing guards.
Wipe clean all filler caps before the engine is serviced or fluids are topped up to reduce the chance of any system
contamination.
For any type of leak (coolant, lubricating oil or fuel), clean away the fluid. If a leak is observed, find the source and correct
the leak. If a leak is suspected, check the fluid levels frequently until the leak is found and repaired.
Accumulated grease and / or oil on an engine is a fire hazard. Remove it by steam cleaning or by the use of a high pressure
water jet. Avoid high-pressure water on the electronic / electrical components provide suitable protection were possible.
Ensure that the coolant pipes are fitted correctly and that they are secure. Check for leaks. Check the condition of all pipes
for splits or signs of rubbing.
Fluid levels
2. Check the engine oil and coolant levels replenish as necessary (see engine handbook for locations). Ensure fluids used are as
recommended within the engine handbook.
Warning:
II Do not remove the radiator cap or any component of the cooling system while the engine is running and while the
coolant is under pressure, because dangerous hot coolant can be discharged, posing a risk of personal injury. Do
not add large amounts of cold coolant to a hot system as serious engine damage could result.
3. Check the engine oil and coolant levels replenish as necessary.
Note:
Diesel engines normally consume lube oil at a rate of 0.25% to 1% of the fuel consumption.
When adding coolant to the radiator system, always pour slowly to help prevent air from becoming trapped in the engine.
Always top up when engine is cold.
Warning:
II When filling the fuel tank, do not smoke or use an open flame in the vicinity.
4. Check the fuel level fill as necessary.
Warning:
II Before tightening the fan belts, disconnect the battery negative () lead to ensure the engine cannot be accidentally
started.
5. Check the condition and tension of the fan and engine alternator belts tighten as necessary.
6. Check all hoses for loose connections or deterioration tighten or replace as necessary.
7. Check the battery terminals for corrosion clean as necessary.
Warning:
II When working with the batteries, do not smoke or use an open flame in the vicinity. Hydrogen gas from batteries is
explosive.
II Do not short the positive and negative terminals together.
41
356-5901(GB) V8 06/13
8. Check the battery electrolyte level fill with distilled water as necessary.
9. Check the control panel and the generator set for heavy accumulation of dust and dirt clean as necessary. These can pose
an electrical hazard or give rise to cooling problems.
10. Check the air filter restriction indicator, if fitted replace the filter as necessary.
11. Clear the area around the generator set of any insecure items that could inhibit operation or cause injury. Ensure cooling air
ventilation screens are clear.
12. Visually check the entire generator set for signs of leaks from the fuel system, cooling system or lubrication seals.
13. Periodically drain exhaust system condensate traps, if equipped.
14. Ensure the Alternator Output Circuit Breaker is in the OFF (handle down) position.
42
356-5901(GB) V8 06/13
43
356-5901(GB) V8 06/13
AUTO pressing the Auto key will cause the engine to enter the auto mode.
MANUAL pressing the Manual key will cause the engine to enter manual mode.
Navigation Keys DCP-10
When in parameter setting mode this button is used to increase values.
44
356-5901(GB) V8 06/13
When in parameter setting mode this button is used to decrease value/scroll up menu.
When in parameter setting mode this button is used to enter into submenu/confirm modification.
When in parameter setting mode this button is used to return to the upper menu.
When in parameter setting mode this button is used to modify the next value.
Used to enter or exit parameter settings, by pressing and holding for 2 seconds.
Event Keys and Indicators:
Mute Button When a failure occurs the alarm buzzer sounds. Pressing the Mute Button will mute the buzzer and the LCD will
display the Mute Icon.
Stop Button Whenever the generator set is at rest pressing the stop button will reset any alarms that have occurred. It will
not reset any active events. If a warning or shutdown occurs either text or a symbol will appear on the display indicating what
the event is. Please refer to the relevant technical manual for the controller for an accurate description of these events.
Display Preferences for DCP-10 Panel
Pressing any push button will illuminate the backlight and will automatically turn off after a preset time. In normal operating
status, you can set the page scroll time to scroll through each screen automatically. Press the scroll button to manually scroll
through each screen. When a failure occurs, the LCD displays the corresponding failure icon.
Whenever the controller is in standby the following data is displayed:
When the controller is running normally it cycles through the following data:
45
356-5901(GB) V8 06/13
Operation
The voltage/current value displayed on this screen is the average value of 3 phases.
Press to scroll to the next page.
Description
U=380V
I=0A
P=0kW
F=50.0Hz
SP=1500rpm
Bat=25.4V
OP=4.6Bar
TEMP=70C
RUN
V1=220V
U12=380V
I1=0A
A1=0kVA
P1=0kW
PF1=1.00
Q1=0kVAr
RUN
V2=220V
U23=380V
I2=0A
A2=0kVA
P2=0kW
PF2=1.00
Q2=0kVAr
RUN
V3=220V
U31=380V
I3=0A
A3=0kVA
P3=0kW
PF3=1.00
Q3=0kVAr
RUN
G. P=0kW
G. A=0kVA
G. Q=0kVAr
G. PF=1.00
RUN
Run Hours = 0.0
This page displays running hours, crank attempt and auxiliary sensor level.
Press to scroll to the next page.
Counters = 0
Fuels = 46%
Heat = 40C
RUN
G. kWHr = 0
This page displays total active and reactive energy.
Press to scroll to the next page.
G. kVArHr = 0
RUN
Relay Outputs:
Relay Outputs refer to the status of configurable relay output.
Digital Inputs refer to the status of configurable inputs.
0 indicates an active Ouput or Input.
Press to scroll to the next page.
46
356-5901(GB) V8 06/13
The switch-mode charger is an automatic battery charger, when the voltage drops
below a preset voltage level it will automatically enter an increased charging voltage
state (Boost). Once the batteries have reached this level, the charger will switch back
to its normal float voltage. This prevents the battery from over charging, which in turn
prevents over gassing and subsequently maximises battery life.
5.5.2 Heaters
Immersion type heaters (engine heaters) may be fitted in the engine coolant system to ensure that the engine is easy to start and
able to take load more quickly.
Alternator anti-condensation heaters (alternator heaters) may be fitted to the alternator stator winding to keep them dry in
humid conditions.
Panel anti-condensation heaters (panel heaters) may be fitted in the control panel to keep moisture levels down.
Control switches are not normally fitted but may be fitted as an additional option. With or without control switches, the heaters
are automatically disconnected on engine start up.
47
356-5901(GB) V8 06/13
Kilowatt (kW) Meter to provide accurate readings of the load being supplied by the generator set, not applicable for
PowerWizard as the PowerWizard 2.1 can display kilowatts.
Lube Oil Temperature Gauge to monitor the lubricating oil temperature when the engine is operating. The normal
operating temperature should be approximately 90 110C (195 230F), not applicable for PowerWizard 1.1 and 2.1+ as
the modules will display this.
Ammeter for Battery Trickle Charger to monitor the current flow to the battery. It is used to observe the charging current
being supplied by the battery trickle charger. When the batteries are fully charged this current will be small
(less than 5 Amps) but with a partially discharged battery this current may be as high as 40 Amps.
48
356-5901(GB) V8 06/13
6. Operation
6.1 Priming Procedure for 1100 Series
Warning:
II Please wear appropriate Personal Protective Equipment (Section 2.2) before carrying out any of the following
procedures as the operator will be in direct contact with diesel fuel. There will also be a risk of spillage.
Note:
Please see engine manual to ascertain engine model. If unsure please consult your local Dealer.
Please see section 3.2 / 3.3 on where the fuel fill can be found on generator set
Following fuel filter servicing or draining of the low pressure fuel system for any reason, re-prime the fuel system as follows.
6.1.1 Products fitted with the small Perkins pre-filter / water separator
a
Note:
Do not open the vent screws (a) when the fuel system is being primed, as diesel fuel will be discharged.
With Fuel Supply from the Base Tank
Operate the priming switch for the standard pre-set 2 minute priming cycle (See section 5.3.10).
Start engine.
In the event of a failure to start the engine within 3 crank cycles, see the Troubleshooting section of this procedure for the
repeat prime procedure.
With Fuel Supply from a Remote Tank
Ensure fuel lines from the remote tank are full of fuel, the pump should never be run when bulk tanks are empty or when
valves on the fuel fill lines are closed.
With the fuel supply switched to remote tank, carry out the priming procedure.
The PowerWizard control panel can be used to energise the fuel lift pump in order to prime the engine as follows:
1. In order to prime the generator set:
MAIN MENU > CONTROL > ENGINE FUEL PRIMING.
2. To prime the set press the right cursor key, this will initiate a 2 minute priming cycle.
3. To exit the priming cycle press the left cursor key.
Note:
The generator set may only be primed when the generator set is stopped and there are no active or present shutdown
conditions.
49
356-5901(GB) V8 06/13
6.1.2 Products fitted with the Racor Pre-Filter / Water Separator (Option)
1
1. T Handle
2. Racor Lid
3. Racor Filter
50
356-5901(GB) V8 06/13
6.1.3 Troubleshooting
Having completed the designated priming procedure, if the engine does not start, there may be air in the Pressure Regulator
Valve (PRV) return loop hose.
B
Figure 6.3 Tooling (Not supplied) & Pressure Regulator Valve (PRV) return loop hose
1. Close the PRV return loop hose (B). Use Tooling (A) in order to close the PRV return loop hose (B). A typical example of Tooling
(A) is shown in the illustration.
2. Repeat the priming procedure that is applicable to the configuration of the fuel system.
3. Release Tooling (A).
4. Start engine. Allow engine to run until smooth operation has been ensured and the pump is free from air.
51
356-5901(GB) V8 06/13
WARNING
II Improper jump start cable connections can cause an explosion resulting in personal injury.
II Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to
contact each other or the engine.
If the installation is not equipped with a backup battery system, it may be necessary to start the engine from an external electrical
source.
After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be
charged to the proper voltage with a battery charger.
Use a battery that is sourced with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The
use of higher voltage will damage the electrical system.
Ensure that the main power switch is in the OFF position before jump start cables are attached to the engine that is being started.
1. Turn the start switch on the stalled engine to the OFF position. Turn off all accessories.
2. Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other
positive end of the jump start cable to the positive cable terminal of the charging or starting source.
3. Connect one negative end of the jump start cable to the negative cable terminal of the charging or starting source. Connect
the other negative end of the jump start cable to the stalled engine block or to the chassis ground. This procedure helps to
prevent potential sparks from igniting combustible gases that are produced by some batteries.
4. Charge the batteries. The engine will not continue to run after starting if the batteries have not been charged.
5. Start the engine.
6. Immediately after the stalled engine is started, disconnect the jump start cables in reverse order.
Consult your local Dealer for more information.
3
IMPORTANT: Connect to ground away from battery.
Away from moving fan and fuel lines
Booster Battery
IMPORTANT: BOTH BATTERIES OR SETS OF BATTERIES MUST HAVE THE SAME VOLTAGES.
DO NOT MIX VOLTAGES
Figure 6.4 - Starting using jump start cables
52
356-5901(GB) V8 06/13
5
1
3
7
1.
2.
3.
4.
5.
6.
7.
enerator set
G
Mains
Load Fed from Generator set
Load Fed from Mains
Two Wire Control
Load Transfer Panel
Load
53
356-5901(GB) V8 06/13
13
12
11
4
10
9
8
Warning
II Maintenance and/or replacement of circuit breakers should only be completed by a fully trained technican.
54
356-5901(GB) V8 06/13
Note:
The engine protection systems e.g. low oil pressure, high coolant temperature, are within the control of the generator set
control panel. These sensors will shut the engine down before the ECM sensors.
55
356-5901(GB) V8 06/13
9. MAINTENANCE
Warning:
II The following procedures should only be carried out by a qualified technician.
A good maintenance programme is the key to long generator set life. Maintenance and service should only be carried out by
qualified technicians. Records of this work should be kept to aid in developing an efficient maintenance programme.
In general, the generator set should be kept clean. Do not permit liquids such as fuel or oil film to accumulate on any internal or
external surfaces or on, under or around any acoustic material, if fitted. Wipe down surfaces using an aqueous industrial cleaner.
Do not use flammable solvents for cleaning purposes.
Any acoustic material with a protective covering that has been torn or punctured should be replaced immediately to prevent
accumulation of liquids or oil film within the material.
Refer to a qualified generator set technician for details of required preventative maintenance.
Batteries contain hazardous materials and in the charged state, each cell contains electrodes of lead metal (Pb) and lead (IV)
dioxide (PbO2) in an electrolyte of about 33.5% w/w (6 Molar) sulphuric acid (H2SO4). In the discharged state both electrodes
turn into lead (II) sulphate (PbSO4) and the electrolyte loses its dissolved sulphuric acid and becomes primarily water.
It can be damaging to the environment to send these to landfill, burning batteries can also cause atmospheric pollution.
Dealing with lead acid batteries can be hazardous so it is important to follow all safety guidelines.
Batteries are an essential part of the generator set and should be maintained appropriately. Keep the battery area clean and dry
and ensure any vent caps are tight (if fitted).
Clean the battery case with one of the following cleaning solutions:
A mixture of 0.1 kg (0.2 lb) of baking soda and 1 L (1 qt) of clean water
A mixture of 0.1 L (0.11 qt) of ammonia and 1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean water.
All battery connections must be kept clean and tight. Use a fine grade of sandpaper to clean the terminals and the cable clamps.
Clean the items until the surfaces are bright or shiny. Do not remove material excessively. Excessive removal of material can
cause a poor connection between the clamps and the battery terminals. Coat the clamps and terminals with grease or other
terminal protector to prevent corrosion.
56
356-5901(GB) V8 06/13
The electrolyte level should be covering the plates/grids (1/2 inch / 13 mm) within the battery to maximize full charge transfer. If
the liquid level is below the plates/grids, only add distilled water; never add battery acid to top up the volume, as the addition of
extra acid will destroy the grids.
It is recommended to check the electrolyte and condition of the batteries every 500 running hours. In high ambient conditions,
it is recommended to use thermal compensation and check electrolyte levels more frequently, for example every 200 running
hours. These checks should also be completed as part of your routine maintenance inspections.
57
356-5901(GB) V8 06/13
Warning:
II The following procedures should only be carried out by a qualified technician.
II Operators should only perform the Pre-Start Check tasks detailed in the Control System Description Section 5.
Daily or at Each Startup:
(For standby generator sets these procedures may be performed weekly.) A walk around inspection should be performed on a
daily basis and prior to starting the engine. The Pre-Start checks contained in Section 5 should be performed during this walk
around. Procedures for performing the checks on the engine can be found in the Engine Manual that may contain additional
requirements to those in Section 6.
Every Two Weeks:
(For standby generator sets that have not been run.) Perform an operational check on the generator set by starting and running it
for only 5 minutes.
Every Month:
(For standby generator sets that have not been run on load.) Perform an operational and load check on the generator set by
starting and running the generator set on at least 50% load for 1 to 2 hours.
Warning:
II Do not run diesel engines at low loads for long periods.
Every Twelve Months or 500 Hours:
Repeat the daily procedures plus the following:
1. Check all control system safety devices by electrically simulating faults.
2. Clean all battery cap vents.
3. Tighten all exhaust connections.
4. Tighten all electrical connections.
5. Perform other engine maintenance as specified in the Engine Manual.
6. Start the engine and observe the instrument panel to ensure that all gauges and meters are operating properly.
58
356-5901(GB) V8 06/13
59
356-5901(GB) V8 06/13
NOTES
60
356-5901(GB) V8 06/13
NOTES
61
356-5901(GB) V8 06/13